U.S. patent application number 13/325349 was filed with the patent office on 2013-05-30 for magnetic pulse forming device for roll forming system and control method for the same.
This patent application is currently assigned to SUNGWOO HITECH CO., LTD.. The applicant listed for this patent is Su Jin Heo, Do-Hoi Koo. Invention is credited to Su Jin Heo, Do-Hoi Koo.
Application Number | 20130133389 13/325349 |
Document ID | / |
Family ID | 48465569 |
Filed Date | 2013-05-30 |
United States Patent
Application |
20130133389 |
Kind Code |
A1 |
Koo; Do-Hoi ; et
al. |
May 30, 2013 |
MAGNETIC PULSE FORMING DEVICE FOR ROLL FORMING SYSTEM AND CONTROL
METHOD FOR THE SAME
Abstract
A magnetic pulse forming device for a roll forming system
includes forward and rearward guide rolling means, a guiding means
including guiding rails disposed on the base between the forward
and rearward guide rolling means and guide frames movably disposed
on the guiding rails, a magnetic forming means including an upper
plate connecting the guide frames corresponding to an upper surface
of the forming beam, a coil housing assembled to the upper plate
and a coil disposed within the coil housing and electrically
connected to a pulse generator to generate a magnetic pulse by
input current, a movement detector, a synchronizing motor connected
to the lead screw to rotate the lead screw and a screw housing
engaged with the lead screw and moving the guide frames with the
forming beam in the process direction by rotation of the lead
screw, and a forming mold.
Inventors: |
Koo; Do-Hoi; (Suwon-si,
KR) ; Heo; Su Jin; (Suwon-si, KR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Koo; Do-Hoi
Heo; Su Jin |
Suwon-si
Suwon-si |
|
KR
KR |
|
|
Assignee: |
SUNGWOO HITECH CO., LTD.
Pusan-city
KR
|
Family ID: |
48465569 |
Appl. No.: |
13/325349 |
Filed: |
December 14, 2011 |
Current U.S.
Class: |
72/60 |
Current CPC
Class: |
B21D 26/14 20130101 |
Class at
Publication: |
72/60 |
International
Class: |
B21D 39/20 20060101
B21D039/20 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 24, 2011 |
KR |
10-2011-0123797 |
Claims
1. A magnetic pulse forming device for a roll forming system,
comprising: forward and rearward guide rolling means disposed on a
base and guiding movement of a forming beam; a guiding means
comprising guiding rails disposed on the base between the forward
and the rearward guide rolling means and guide frames movably
disposed on the guiding rails; a magnetic forming means comprising
an upper plate connecting the guide frames corresponding an upper
surface of the forming beam, a coil housing assembled to the upper
plate and a coil disposed within the coil housing and electrically
connected to a pulse generator to generate a magnetic pulse by
input current; a movement detector detecting movement of the
forming beam; a synchronizing means comprising a lead screw
disposed along the base, a synchronizing motor connected to the
lead screw to rotate the lead screw, and a screw housing engaged
with the lead screw and moving the guide frames with the forming
beam in the process direction by rotation of the lead screw; and a
forming mold that is disposed on the screw housing through an
ascending/descending cylinder corresponding to the magnetic forming
means and that supports a lower surface of the forming beam and the
forming mold to which a forming surface for forming a predetermined
shape to the forming beam by the electromagnetic force generated
from the coil is formed.
2. The magnetic pulse forming device of claim 1, wherein each
forward and rearward guide rolling means comprises: a roll frame
disposed on the base; a lower guiding roller disposed to the roll
frame through a slider and guiding the lower surface of the forming
beam; and an upper guiding roller disposed to the roll frame
through a slider and guiding the upper surface of the forming
beam.
3. The magnetic pulse forming device of claim 1, wherein the
guiding means further comprises a slide block disposed on the
guiding rail and vertically connected to the guide frame.
4. The magnetic pulse forming device of claim 1, wherein the
magnetic forming means further comprises a field shaper disposed
near the coil and assembled to the coil housing for focusing the
magnetic pulse on the upper surface of the forming beam.
5. The magnetic pulse forming device of claim 4, wherein a
protrusion is formed to the field shaper focusing the magnetic
pulse to a forming portion.
6. The magnetic pulse forming device of claim 1, wherein the
movement detector comprises: a rotating roller contacting the
forming beam and rotating according to movement of the forming
beam; and an encoder detecting the rotation of the rotating roller
and outputting a rotation signal to a controller.
7. The magnetic pulse forming device of claim 6, wherein the
rotating roller is made of a rubber material.
8. The magnetic pulse forming device of claim 1, wherein the
synchronizing means further comprises a return switch that is
disposed to the guiding rail, detects movement of the guide frame,
and outputs a return signal to the controller.
9. The magnetic pulse forming device of claim 1, wherein the
synchronizing motor is a servo motor configured to control rotation
speed and rotating direction.
10. The magnetic pulse forming device of claim 1, wherein the
ascending/descending cylinder is a hydraulic cylinder, and the
forming mold is disposed on an end of a rod that is raised or
lowered by the operation of the ascending/descending cylinder.
11. The magnetic pulse forming device of claim 1, wherein a guide
groove is formed to the guide frame along up and down directions,
and a guide protrusion is formed to the forming mold to be guided
along the guide groove.
12. The magnetic pulse forming device of claim 1, wherein a forming
groove corresponding to the forming beam and having a predetermined
shape is formed to the forming surface.
13. A control method for a magnetic pulse forming device for a roll
forming system, the control method comprising: detecting rotation
speed of a rotating roller according to movement of a forming beam
from an encoder and a return signal from a return switch;
calculating moving speed of the forming beam according to the
rotation speed of the rotating roller; determining whether a
current section of the forming beam is a forming section of the
forming beam; raising a forming mold by operation of an
ascending/descending cylinder, and simultaneously operating a
synchronizing motor forward for moving a magnetic forming means
with the forming mold synchronized with moving speed of the forming
beam if the current section of the forming beam is the forming
section of the forming beam; controlling a pulse generator of the
magnetic forming means to form and discharge a magnetic pulse to
the forming beam using the magnetic pulse and the forming mold;
detecting the return signal from the return switch; and operating
the ascending/descending cylinder to lower the forming mold and
simultaneously controlling the synchronizing motor rearward for
moving the magnetic forming means with the forming mold to the
original position if the return signal is detected.
14. The control method of claim 13, wherein the magnetic forming
means comprising: the pulse generator that discharges high voltage
electrical energy stored to a condenser to generate a pulse
current; a coil housing disposed corresponding to the forming beam;
a coil disposed within the coil housing and electrically connected
to the pulse generator to generate a magnetic pulse by input
current from the pulse generator; and a field shaper disposed near
the coil and assembled to the coil housing for focusing the
magnetic pulse on the upper surface of the forming beam.
15. The control method of claim 13, wherein the encoder detects the
rotation speed of the rotating roller according to the movement of
the forming beam and outputs rotation speed signal to a
controller.
16. The control method of claim 13, wherein the synchronizing motor
is controlled to rotate to move the magnetic forming means with the
forming mold synchronized with the moving speed of the forming
beam.
17. The control method of claim 16, wherein the synchronizing motor
is a servo motor configured to control rotation speed and rotating
direction.
18. The control method of claim 13, wherein the
ascending/descending cylinder is a hydraulic cylinder.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to and the benefit of
Korean Patent Application No. 10-2011-0123797 filed in the Korean
Intellectual Property Office on Nov. 24, 2011, the entire contents
of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] (a) Field of the Invention
[0003] The present invention relates to a magnetic pulse forming
device for a roll forming system and a control method for the same.
More particularly, the present invention relates to a magnetic
pulse forming device for a roll forming system and a control method
for the same that may form a bead portion for reinforcement using
electromagnetic force.
[0004] (b) Description of the Related Art
[0005] A straight-type beam, such as a bumper beam, is manufactured
by a roll forming apparatus including a plurality of roll formers
that consist of an upper roller and a lower roller and are disposed
in series. The roll formers bend a panel into various shapes.
[0006] FIG. 1 is a schematic diagram showing a conventional
roll-forming system and respective steps of a roll-forming method
using the same.
[0007] Referring to FIG. 1, a roll forming system includes an
uncoiler 201 provided at a front portion in a process line and
performing an uncoiling step S110 where a coil 210 is uncoiled.
[0008] A straightener 203 is provided at the rear of the uncoiler
201 in the process line and performs a straightening step S120
where the coil 210 supplied from the uncoiler 201 is straightened
to be a panel 220.
[0009] In addition, the roll forming apparatus further includes a
brake press 205 provided at the rear of the straightener 203 and
performing a piercing step S130 where a plurality of holes for
assembling a bumper beam are bored in the panel 220 supplied from
the straightener 203.
[0010] A roll former unit 207 including a plurality of roll formers
R1, R2, R3, R4, R5, R6, and R7 is provided at the rear of the brake
press 205 in the process line. The roll former unit 207 performs a
roll-forming step S140 by sequentially bending the panel 220
supplied through the uncoiler 201, the straightener 203, and the
brake press 205 to be a predetermined-shaped beam 230 as shown in
FIG. 2.
[0011] A round bender 209 including at least one of
curvature-forming rolls disposed at both sides thereof is provided
at the rear of the roll former unit 207 in the process line. The
shaped beam, having gone through the roll-forming step S140, passes
through the round bender 209 and is bent to have a predetermined
curvature. Thereby, a bending step S150 is performed.
[0012] In addition, a cutting press 211 for cutting the shaped beam
to have a predetermined dimension is provided at the rear of the
round bender 209 in the process line, and performs a cutting step
S160.
[0013] The above roll forming system and process may produce the
formed beam 240 (shaped beam) as shown in FIG. 2, which may be a
bumper beam 300 for a vehicle that is an open type along the length
direction with a predetermined shape and bend.
[0014] However, a center portion of the bumper beam 300 may be weak
to impact energy compared to both ends supported by a stay.
Particularly, in a head-on collision, deformation of and damage to
the center portion may be serious.
[0015] For reinforcing the center portion of the bumper beam, a
reinforcing member may be provided to the center portion or a
separate support beam may be applied thereto. However, an
additional process is required and weight and manufacturing cost
may be increased.
[0016] Thus, research and development for partially reinforcing the
bumper beam in the roll forming process with a low cost and without
increasing weight is required.
[0017] The above information disclosed in this Background section
is only for enhancement of understanding of the background of the
invention and therefore it may contain information that does not
form the prior art that is already known in this country to a
person of ordinary skill in the art.
SUMMARY OF THE INVENTION
[0018] The present invention has been made in an effort to provide
a roll forming system and a control method for the same having
advantages of forming a reinforcement portion without affecting
manufacturing cycle time in a rolling forming line.
[0019] Particularly, in an exemplary embodiment of the present
invention, a magnetic pulse forming device for a roll forming
system and a control method for the same may form a bead portion
for reinforcement using electromagnetic force synchronized with
roll forming speed.
[0020] A magnetic pulse forming device for a roll forming system
according to an exemplary embodiment of the present invention may
include forward and rearward guide rolling means disposed on a base
and guiding movement of a forming beam, a guiding means including
guiding rails disposed on the base between the forward and rearward
guide rolling means and guide frames movably disposed on the
guiding rails, a magnetic forming means including an upper plate
connecting the guide frames corresponding to an upper surface of
the forming beam, a coil housing assembled to the upper plate and a
coil disposed within the coil housing and electrically connected to
a pulse generator to generate a magnetic pulse by input current, a
movement detector detecting movement of the forming beam, a
synchronizing means including a lead screw disposed along the base,
a synchronizing motor connected to the lead screw to rotate the
lead screw and a screw housing engaged with the lead screw and
moving the guide frames with the forming beam in the process
direction by rotation of the lead screw, and a forming mold that is
disposed on the screw housing through an ascending/descending
cylinder corresponding to the magnetic forming means and that
supports a lower surface of the forming beam and the forming mold
to which a forming surface for forming a predetermined shape to the
forming beam by the electromagnetic force generated from the coil
is formed.
[0021] Each forward and rearward guide rolling means may include a
roll frame disposed on the base, a lower guiding roller disposed to
the roll frame through a slider and guiding the lower surface of
the forming beam, and an upper guiding roller disposed to the roll
frame through a slider and guiding the upper surface of the forming
beam.
[0022] The guiding means further may include a slide block disposed
on the guiding rail and vertically connected to the guide
frame.
[0023] The magnetic forming means may further include a field
shaper disposed near the coil and assembled to the coil housing for
focusing the magnetic pulse on the upper surface of the forming
beam.
[0024] A protrusion may be formed to the field shaper focusing the
magnetic pulse to a forming portion.
[0025] The movement detector may include a rotating roller
contacting the forming beam and rotating according to movement of
the forming beam, and an encoder detecting the rotation of the
rotating roller and outputting a rotation signal to a
controller.
[0026] The rotating roller may be made of a rubber material.
[0027] The synchronizing means may further include a return switch
that is disposed to the guiding rail, detects movement of the guide
frame, and outputs a return signal to the controller.
[0028] The synchronizing motor may be a servo motor configured to
control rotation speed and rotating direction.
[0029] The ascending/descending cylinder may be a hydraulic
cylinder, and the forming mold may be disposed on an end of a rod
that is raised or lowered by the operation of the
ascending/descending cylinder.
[0030] A guide groove may be formed to the guide frame along up and
down directions, and a guide protrusion may be formed to the
forming mold to be guided along the guide groove.
[0031] A forming groove corresponding to the forming beam and
having predetermined shape may be formed to the forming
surface.
[0032] A control method for a magnetic pulse forming device for a
roll forming system, the control method may include detecting
rotation speed of a rotating roller according to movement of a
forming beam from an encoder and a return signal from a return
switch, calculating moving speed of the forming beam according to
the rotation speed of the rotating roller, determining whether a
current section of the forming beam is a forming section of the
forming beam, raising a forming mold by operation of an
ascending/descending cylinder and simultaneously operating a
synchronizing motor forward for moving a magnetic forming means
with the forming mold synchronized with moving speed of the forming
beam if the current section of the forming beam is the forming
section of the forming beam, controlling a pulse generator of the
magnetic forming means to form and discharge a magnetic pulse to
the forming beam using the magnetic pulse and the forming mold,
detecting the return signal from the return switch and operating
the ascending/descending cylinder to lower the forming mold and
simultaneously controlling the synchronizing motor rearward for
moving the magnetic forming means with the forming mold to the
original position if the return signal is detected.
[0033] The magnetic forming means may include the pulse generator
that discharges high voltage electrical energy stored to a
condenser to generate pulse current, a coil housing disposed
corresponding to the forming beam, a coil disposed within the coil
housing and electrically connected to the pulse generator to
generate a magnetic pulse by input current from the pulse
generator, and a field shaper disposed near the coil and assembled
to the coil housing for focusing the magnetic pulse on the upper
surface of the forming beam.
[0034] The encoder may detect the rotation speed of the rotating
roller according to the movement of the forming beam and output
rotation speed signal to a controller.
[0035] The synchronizing motor may be controlled to rotate to move
the magnetic forming means with the forming mold synchronized with
the moving speed of the forming beam.
[0036] The synchronizing motor may be controlled to rotate to move
the magnetic forming means with the forming mold synchronized with
the moving speed of the forming beam.
[0037] The ascending/descending cylinder may be a hydraulic
cylinder.
[0038] A roll forming system and a control method for the same
according to the exemplary embodiment of the present invention may
form a reinforced portion for reinforcement without affecting
manufacturing cycle time in a rolling forming line with a low cost
and without increasing weight.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1 is a schematic diagram showing a conventional
roll-forming system and respective steps of a roll-forming method
using the same.
[0040] FIG. 2 is a perspective view of a bumper beam manufactured
by a conventional roll forming apparatus and a method thereof.
[0041] FIG. 3 is a schematic diagram of a roll forming apparatus to
which a magnetic pulse forming device according to an exemplary
embodiment of the present invention is applied and respective steps
of a roll-forming method using the same.
[0042] FIG. 4 is a side view of a magnetic pulse forming device
according to an exemplary embodiment of the present invention.
[0043] FIG. 5 is a cross-sectional view along line A-A of FIG.
4.
[0044] FIG. 6 is a control block diagram of a control method for a
magnetic pulse forming device according to an exemplary embodiment
of the present invention.
[0045] FIG. 7 is a drawing showing operations of a magnetic pulse
forming device according to an exemplary embodiment of the present
invention.
[0046] FIG. 8 is a flowchart of a control method for a magnetic
pulse forming device according to an exemplary embodiment of the
present invention.
[0047] FIG. 9 is a perspective view of a bumper beam manufactured
by a roll forming apparatus applied with a magnetic pulse forming
device and a control method for the same according to an exemplary
embodiment of the present invention.
TABLE-US-00001 <Description of Symbols> 1: uncoiler 2:
straightener 3: brake press 4: roll forming unit 5: magnetic pulse
forming device 6: round bender 7: cutting press 9: base 10: coil
20: panel 30, 40, 50, 60: forming beam 110, 120: guide rolling
means 130: guiding means 140: magnetic forming means 150: movement
detector 160: synchronizing means 170: forming mold 111, 121: roll
frame 113, 123, 117, 127: slider 115, 125, 119, 129: guiding roller
131: guiding rail 133: slide block 135: guide frame 137: upper
plate 141: pulse generator 143: coil housing 145: coil 147: field
shaper 151: rotating roller 153: encoder 161: screw housing 163:
connecting bracket 165: lead screw 167: synchronizing motor 169:
return switch 171: ascending/descending cylinder 175: guide groove
177: guide protrusion V: moving speed C: controller
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0048] Exemplary embodiments of the present invention will
hereinafter be described in detail with reference to the
accompanying drawings.
[0049] For better comprehension and ease of description, parts
unrelated to explanation may be omitted, and like numerals refer to
like elements throughout the specification. In the drawings, the
thickness of layers, films, panels, regions, etc., are exaggerated
for clarity.
[0050] FIG. 3 is a schematic diagram of a roll forming apparatus to
which a magnetic pulse forming device according to an exemplary
embodiment of the present invention is applied and respective steps
of a roll-forming method using the same, FIG. 4 is a side view of a
magnetic pulse forming device according to an exemplary embodiment
of the present invention, and FIG. 5 is a cross-sectional view
along line A-A of FIG. 4.
[0051] Referring to FIG. 3, a magnetic pulse forming device 5
according to an exemplary embodiment of the present invention is
provided at the rear of a roll forming unit including a plurality
of roll formers R1, R2, R3, . . . , R6, and R7, and performs
magnetic pulse forming to a forming beam (shaped beam) 30 with a
predetermined shape.
[0052] A roll forming system to which the magnetic pulse forming
device 5 according to an exemplary embodiment of the present
invention may be applied includes an uncoiler 1 provided at a front
portion in a process line, and a coil 10 is uncoiled from the
uncoiler 1.
[0053] A straightener 2 is provided at the rear of the uncoiler 1
in the process line and straightens the coil 10 supplied from the
uncoiler 1 to be a panel 20.
[0054] A brake press 3 is provided at the rear of the straightener
2 and pierces the panel 20 to form a plurality of holes for
assembling a bumper beam supplied from the straightener 2.
[0055] A roll former unit 4 is provided at the rear of the brake
press 3 in the process line. The roll former unit 4 sequentially
bends the panel 20 supplied from the straightener 3 to be a
predetermined-shaped beam (forming beam) 30.
[0056] The roll former unit 4 includes a plurality of roll formers
R1, R2, R3, R4, R5, R6, and R7 disposed sequentially.
[0057] The magnetic pulse forming device 5 according to an
exemplary embodiment of the present invention is provided at the
rear of the roll forming unit 4, as shown in FIG. 4, to perform
magnetic pulse forming of the forming beam 30.
[0058] A round bender 6 including at least one of curvature-forming
rolls disposed at both sides thereof is provided at the rear of the
magnetic pulse forming device 5 in the process line. A shaped beam
(forming beam) 40, having passed through the round bender 6, is
bent to have a predetermined curvature.
[0059] In addition, a cutting press 7 for cutting a shaped beam
(forming formed beam) 50 to have a predetermined dimension is
provided at the rear of the round bender 6.
[0060] Referring to FIG. 4 and FIG. 5, the magnetic pulse forming
device 5 includes forward and rearward guide rolling means 110 and
120, a guiding means 130, a magnetic forming means 140, a movement
detector 150, a synchronizing means 160, and a forming mold
170.
[0061] The forward and rearward guide rolling means 110 and 120 are
disposed on the base 9 between the last roll former (i.e., R7 of
FIG. 3) of the roll forming unit 4 and the round bender 6, and
guides the forming beam 30.
[0062] The forward and rearward guide rolling means 110 and 120 may
have the same function and scheme, and include a roll frame 111 and
121 disposed on the base 9, respectively.
[0063] Lower guiding rollers 115 and 125 are respectively disposed
to lower portions of the roll frames 111 and 121 through respective
sliders 113 and 123 to rotatably support a lower surface of the
forming beam 30.
[0064] Upper guiding rollers 119 and 129 are respectively disposed
to upper portions of the roll frames 111 and 121 through respective
sliders 117 and 127 to rotatably support an upper surface of the
forming beam 30.
[0065] The forward and rearward guide rolling means 110 and 120
guide the forming beam 30 that is roll-formed by the roll forming
unit 4 at a constant speed through each of the upper and lower
guiding rollers 119, 129, 115 and 125.
[0066] The upper and lower guiding rollers 119, 129, 115, and 125
may ease spring-back that may be generated by remaining residual
stress in the roll forming process of the forming beam 30 and thus
deformation may be prevented in the magnetic pulse forming process
performed by the magnetic pulse forming device 5.
[0067] The guiding means 130 is disposed on the base 9 between the
forward and rearward guide rolling means 110 and 120 along the
process direction.
[0068] The guiding means 130 includes guiding rails 131 disposed
along the process direction.
[0069] A slide block 133 is slidably disposed on each guiding rail
131 and a guide frame 135 is vertically disposed on each slide
block 133.
[0070] An upper plate 137 connects upper portions of the guide
frames 135.
[0071] The magnetic forming means 140 is disposed to the upper
plate 137 corresponding to the upper surface of the forming beam
30, generates electromagnetic force using a high voltage current
input from a pulse generator 141, and performs magnetic pulse
forming using the electromagnetic force to the forming beam 30.
[0072] The pulse generator 141 discharges high voltage electrical
energy stored to a condenser (not shown) to generate the pulse
current.
[0073] A coil housing 143 is mounted to a lower portion of the
upper plate 137 and a coil 145 is disposed within the coil housing
143.
[0074] The coil 145 is electrically connected to the pulse
generator 141, and may be an induction coil used to generate the
magnetic pulse using the pulse current input from the pulse
generator 141.
[0075] A field shaper 147 is disposed near the coil 145 and
assembled to the coil housing 143, and focuses the magnetic pulse
on the upper surface of the forming beam 30.
[0076] A protrusion 149 may be formed to the field shaper 147 to
integrally focus the magnetic pulse on a forming portion of the
forming beam 30.
[0077] The movement detector 150 detects movement of the forming
beam 30 for calculating moving speed of the forming beam 30 and
determining whether a current section of the forming beam 30 is a
forming section of the forming beam 30.
[0078] The movement detector 150 includes a rotating roller 151
that contacts the forming beam 30 and rotates around an encoder
shaft 155 according to the movement of the forming beam 30, and an
encoder 153 that detects the rotation of the rotating roller 151
and outputs the rotation signal.
[0079] The encoder 153 outputs the rotation speed signal of the
rotating roller 151 according to the movement of the forming beam
30 to a controller C, and the controller C calculates the moving
speed of the forming beam 30 and determines whether the current
section of the forming beam 30 is the forming section of the
forming beam 30.
[0080] The rotating roller 151 may be made of a rubber material, a
resin such as silicon, and so on to enhance the contact
characteristic.
[0081] The synchronizing means 160 is disposed between the guiding
rails 131 on the base 9 and synchronizes movement of the guide
frames 135 to the moving speed of the forming beam 30 along the
process direction.
[0082] The synchronizing means 160 includes a screw housing 161
disposed between the guide frames 135, and the screw housing 161 is
connected to the guide frame 135 through a connecting bracket
163.
[0083] The screw housing 161 is engaged with a lead screw 165, and
both ends of the lead screw 165 are rotatably disposed to bearing
units BU on the base 9.
[0084] A synchronizing motor 167 is disposed to one of the bearing
units BU, and a rotation shaft of the synchronizing motor 167 is
connected to the lead screw 165 to drive the lead screw 165.
[0085] The synchronizing motor 167 may be a servo motor configured
to control rotation speed and rotating direction.
[0086] A return switch 169 is disposed to a rear portion of the
guiding rail 131, detects the guide frame 135, and outputs a return
signal to the controller C.
[0087] The forming mold 170 is disposed on an ascending/descending
cylinder 171 that is disposed on the screw housing 161
corresponding to the field shaper 147 of the magnetic forming means
140.
[0088] The ascending/descending cylinder 171 may be a hydraulic
cylinder using hydraulic pressure controlled by a solenoid valve SV
disposed on a hydraulic pressure line L.
[0089] The forming mold 170 is disposed on an end of a rod 173,
which ascends or descends by the operation of the
ascending/descending cylinder 171, and ascends or descends between
the guide frames 135.
[0090] The forming mold 170 has a forming surface F that supports
the lower surface of the forming beam 30 when the coil 145
generates the electromagnetic force to perform the magnetic pulse
forming to the forming beam 30, and a forming groove G is formed to
the forming surface F with a predetermined shape corresponding to
the lower surface of the forming beam 30.
[0091] A guide groove 175 is formed to each guide frame 135 along
up and down directions, and guide protrusions 177 are formed to the
forming mold 170 to be guided by the guide grooves 175.
[0092] As shown in FIG. 6, the controller C receives the rotation
speed signal of the rotating roller 151 from the encoder 153 and
the return signal from the return switch 169, and calculates the
moving speed V of the forming beam 30 according to the rotation
speed signal and determines whether the current section of the
forming beam 30 is the forming section of the forming beam 30, and
determines synchronizing return time according to the return
signal.
[0093] Also, the controller C controls the synchronizing speed of
the magnetic forming means 140 by motor output control of the
synchronizing motor 167, and controls discharging time of the pulse
generator 141. The controller C controls operations of the
ascending/descending cylinder 171 by controlling ON and OFF of the
solenoid valve SV.
[0094] Hereinafter, referring to FIG. 3, operations of the magnetic
pulse forming device 5 will be described.
[0095] The uncoiler 1 supplies the coil 10 at the initial process
line to perform an uncoiling step S1.
[0096] After the uncoiling step S1, the straightener 2 provided at
the rear of the uncoiler 1 straightens the coil 10 to become the
panel 20 to perform a straightening step S2.
[0097] The brake press 3 provided at the rear of the straightener 2
performs a piercing step S3 where a plurality of holes for
assembling the forming beam are bored in the panel 20 supplied from
the straightener 2.
[0098] The roll former unit 4 including a plurality of roll formers
R1, R2, R3, R4, R5, R6, and R7 provided at the rear of the brake
press 3 in the process line performs a roll-forming step S4 by
sequentially bending the panel 20 supplied through the brake press
3 to be the predetermined-shaped beam 30.
[0099] The magnetic pulse forming device 5 provided at the rear of
the roll forming unit 4 as shown in FIG. 4 and FIG. 5 performs a
magnetic pulse forming step S5 according to the control method
shown in FIG. 8 for forming a bead portion 61 for reinforcement
while synchronizing the forming beam 30.
[0100] The round bender 6 provided at the rear of the magnetic
pulse forming device 5 in the process line performs bending step S6
to bend the forming beam 40 be have a predetermined curvature.
[0101] The cutting press 7 provided at the rear of the round bender
6 performs cutting step S7 by cutting the forming beam 50 supplied
from bending step S6 to have a predetermined dimension. Thus, as
shown in FIG. 9, the bead 61 for reinforcement is formed to the
center of the forming beam 60.
[0102] Hereinafter, a control method for the magnetic pulse forming
device 5 according to an exemplary embodiment of the present
invention will be described referring to FIG. 8.
[0103] The controller C receives the rotation speed signal of the
rotating roller 151 from the encoder 153 and the return signal from
the return switch 169 (ST1).
[0104] Then the controller C calculates the moving speed V of the
forming beam 30 according to the rotation speed signal and
determines a synchronizing return time according to the return
signal (ST2).
[0105] The controller C determines whether the current section of
the forming beam 30 is the forming section of the forming beam 30
(ST3).
[0106] If the current section of the forming beam 30 is not the
forming section of the forming beam 30, it returns to step ST1.
[0107] If the current section of the forming beam 30 is the forming
section of the forming beam 30, the controller C controls the
solenoid valve SV to operate the ascending/descending cylinder 171
in order to raise the forming mold 170, and simultaneously the
controller C controls the synchronizing motor 167 to move the
magnetic forming means 140 with the forming mold 170 synchronized
with the moving speed V of the forming beam 30 (ST4).
[0108] As shown in FIG. 7, the forming mold 170 ascends to contact
the lower surface of the forming beam 30, and the magnetic forming
means 140 and the forming mold 170 move along the process direction
synchronized with the moving speed V of the forming beam 30.
[0109] Then, the controller C controls the pulse generator 141 of
the magnetic forming means 140 to discharge high voltage
electricity stored in the condenser (not shown) through the coil
145.
[0110] The magnetic pulse, as shown in FIG. 7, is then focused on
the forming beam 30 through the field shaper 147 and performs the
magnetic pulse forming (ST5).
[0111] The controller C then determines whether a return signal is
detected from the return switch 169 (ST6)
[0112] If the controller C detects the return signal, the
controller C controls the solenoid valve SV to operate the
ascending/descending cylinder 171 in order to lower the forming
mold 170, and simultaneously the controller C controls the
synchronizing motor 167 to move the forming mold 170 with the
magnetic forming means 140 to the original position (ST7).
[0113] As shown in FIG. 5, the forming mold 170 then descends to be
separated from the lower surface of the forming beam 30, and the
forming mold 170 and the magnetic forming means 140, as shown in
FIG. 4, return along the opposite direction of the process to the
original position.
[0114] While this invention has been described in connection with
what is presently considered to be practical exemplary embodiments,
it is to be understood that the invention is not limited to the
disclosed embodiments, but, on the contrary, is intended to cover
various modifications and equivalent arrangements included within
the spirit and scope of the appended claims.
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